Removal And Installation: Turbocharger: Installation

All vehicles 

• 1.
  
  
  NOTE: Make sure that new turbocharger mounting studs and a new turbocharger gasket are installed.

  Install and tighten the turbocharger mounting studs. Install a new turbocharger gasket.

  Torque: 150 lb.in (17 Nm)

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• 2.
  
  If the turbocharger coolant tube was removed from the turbocharger, install the new linked sealing washers.

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• 3.
  
  If removed, install the turbocharger coolant tube to the turbocharger.

  Torque:

  1: 21 lb.ft (28 Nm)

  2: 89 lb.in (10 Nm)

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• 4.
  
  
  NOTE: Make sure that new turbocharger nuts are installed.

  Install the turbocharger, then install and tighten the turbocharger mounting nuts in the sequence shown.

  Torque: 37 lb.ft (50 Nm)

AWD (all-wheel drive) vehicles 

• 5.
  
  

  • 1.
    
    Attach the vacuum tubes. Early build vehicles equipped with metal vacuum tubes.

  • 2.
    
    Attach the vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.

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• 6.
  
  Raise the jack and position the engine back.

  Use the General Equipment: Trolley Jack

  Use the General Equipment: Wooden Block

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• 7.
  
  Install the engine mount. Refer to: Engine Mount .

All vehicles 

• 8.
  
  
  NOTE: Make sure that a new turbocharger oil drain tube and that new turbocharger oil drain tube gaskets are installed. By not doing so, the turbocharger oil drain tube may leak and cause engine damage.

  Install the new turbocharger oil return tube gaskets.

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• 9.
  
  Install the new turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

  Torque: 89 lb.in (10 Nm)

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• 10.
  
  
  NOTE: Do not reuse the turbocharger oil filter, a new turbocharger oil filter must be installed.

  Install the new turbocharger oil filter.

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• 11.
  
  
  NOTE: Make sure that 4 new turbocharger oil supply tube sealing washers are installed.

  Install the turbocharger oil supply tube and then install and tighten the turbocharger oil supply tube retaining bolts.

  Torque: 18 lb.ft (25 Nm)

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• 12.
  
  Connect the turbocharger electrical connector and connect the turbocharger control hoses.

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• 13.
  
  Install the turbocharger heat shield, then install and tighten the turbocharger heat shield bolts.

  Torque: 89 lb.in (10 Nm)

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• 14.
  
  
  NOTE: Make sure that 2 new turbocharger coolant tube linked sealing washers are installed.
  NOTE: Both water outlet tube clamps must be installed between the 2 paint stripes on hoses.

  Install the turbocharger cooling tube assembly, then install and tighten the turbocharger cooling tube bolts.

  Torque: 21 lb.ft (28 Nm)

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• 15.
  
  

  • 1.
    
    Install turbocharger inlet pipe, tighten the clamp.

    Torque: 44 lb.in (5 Nm)

  • 2.
    
    Install and tighten the turbocharger inlet pipe retainers.

    Torque: 97 lb.in (11 Nm)

  • 3.
    
    Connect the quick release coupling. Refer to: Quick Release Coupling .

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• 16.
  
  

  • 1.
    
    Install and tighten the turbocharger outlet pipe retaining nuts.

    Torque: 97 lb.in (11 Nm)

  • 2.
    
    Install the turbocharger outlet pipe and then tighten the turbocharger outlet pipe clamps.

    Torque: 44 lb.in (5 Nm)

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• 17.
  
  Install the right front tire. Refer to: Wheel and Tire .

• 18.
  
  Install the catalytic converter. Refer to: Catalytic Converter .

• 19.
  
  Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling And Bleeding .